‘Do Not Drive’ advisory: Jeep issues engine recall for Wrangler 4xe, Grand Cherokee 4xe due to sand contamination

AUBURN HILLS, Mich. — Stellantis is recalling nearly 113,000 Jeep Wrangler 4xe and Grand Cherokee 4xe SUVs after federal safety regulators said in public filings that some engines may contain sand left behind during the casting process, creating a risk of catastrophic engine failure or fire.

According to documents filed with the National Highway Traffic Safety Administration (NHTSA), certain engines supplied for Jeep’s plug-in hybrid SUVs were not properly cleaned during the casting process. Sand can remain trapped inside the engine block, break loose over time, and circulate through internal components. Regulators say that can cause overheating, internal damage, and “unexpected and unrecoverable loss of propulsion,” as well as engine-compartment fires.

The issue affects engines built between June 7, 2023, and March 4, 2025, at a supplier facility in Mexico, according to NHTSA.

The impacted vehicles include:

• 2024–2025 Jeep Wrangler 4xe
• 2023–2025 Jeep Grand Cherokee 4xe

Stellantis has issued a “Do Not Drive” and “Park Outside” advisory for all affected SUVs while a long-term fix is developed. The company reported 36 fires, 50 loss-of-propulsion incidents and more than 140 warranty claims potentially tied to the defect across all markets, according to federal filings.

The Wrangler 4xe, Jeep’s first plug-in hybrid version of its flagship SUV, entered production in December 2020 at the Toledo Assembly Complex, according to a Stellantis media release. The model debuted in the 2021 model year as part of Jeep’s move toward electrification, pairing a 2.0-liter turbocharged engine with electric motors and a rechargeable battery system. While the Wrangler 4xe is built in Toledo alongside its gasoline-powered counterparts, the Grand Cherokee 4xe – introduced shortly afterward – is assembled at the Detroit Assembly Complex – Mack plant.

NHTSA says some drivers may receive early warning signs, including:

• A knocking noise coming from the engine
• A malfunction indicator lamp (MIL) or check-engine light

However, regulators warn that catastrophic failure can still occur without warning.

Vehicle Identification Numbers (VINs) for this recall became searchable on Nov. 13 on NHTSA.gov.

Stellantis will mail interim owner notification letters between Dec. 29 and Dec. 31, 2025, with full remedy instructions to follow in phases once repairs are finalized. A permanent fix is still under development.

Owners can check their VIN at NHTSA.gov/recalls or call the Stellantis hotline at 1-800-853-1403.

This engine-sand recall is separate from battery and software issues in other 4xe models, and is the latest in a series of safety campaigns affecting Jeep’s plug-in hybrid lineup.

• Battery recall (2020–2024 Wrangler 4xe, 2022–2024 Grand Cherokee 4xe): A previous major recall involves certain high-voltage battery packs that may contain cells with internal separator damage. That defect can lead to a vehicle fire, and owners were advised to stop charging their vehicles and park away from structures until repairs are completed. The remedy includes a software update and potential battery-pack replacement.
• Hybrid software recall (2022–2026 Grand Cherokee 4xe): Another active recall covers a software-related issue that can cause the hybrid system to shut down without warning. Stellantis has said an intermittent communication fault between hybrid control modules may lead to sudden loss of propulsion. Updated software will be installed at no charge once available.

These issues affect different model years, so owners are encouraged to check their VINs even if they believe their vehicle is not included.

WTOL 11 compiled the steps owners should take:

1. Check your VIN immediately. Visit NHTSA.gov/recalls and enter your 17-digit VIN. VINs for the sand-engine recall are already searchable.
2. Follow the safety guidance. For the sand contamination recall, Stellantis advises do not drive the vehicle. Park it outside, away from homes, garages and structures. For the battery recall, Stellantis advises do not charge the vehicle and continue parking outdoors. 
3. Watch for early symptoms. If you hear knocking or see warning lights, federal regulators say that may indicate engine contamination.
4. Wait for official notice. Interim letters will begin arriving Dec. 29–31, with repair details to follow. 
5. Contact your dealer with questions. Repairs will be free once the remedy is finalized.

WTOL 11 previously reported on a Monroe County family pursuing a lemon-law case involving their 2023 Grand Cherokee 4xe, including an incident where the vehicle lost power on I-75. That case is ongoing. 

At the time of reporting in September, Stellantis provided WTOL 11 with the following statement:

“The safety of our customers is a top priority, and the Company is actively deploying a remedy for this campaign. FCA US is voluntarily recalling an estimated 91,787 U.S.-market vehicles to update their hybrid control processor (HCP) software. 

An internal investigation determined that some 2022–2026 model-year Jeep® Grand Cherokee plug-in hybrid electric vehicles (PHEV) may experience an intermittent communication issue between the battery pack control module (BPCM) and the hybrid control processor (HCP). In certain instances, the HCP may misinterpret a signal from the BPCM. If this happens, it could result in the propulsion system shutting down without warning and increase the risk of a collision.”

At the time, the company said it was unaware of any related accidents or injuries.